ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

Transcription

1 CENTURION Owner s Manual Liquid-cooled, Prepackaged Standby Generators Model No kW NG, kw LP This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

2 INTRODUCTION Thank you for purchasing this model of the Centurion standby generator set product line by Generac Power Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact the nearest Generac Authorized Service Dealer for starting, operating and servicing procedures. Please note that a fee may be charged if a service call is made to the location. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: DANGER After this heading, read instructions that, if not strictly complied with, will result in severe personal injury, including death or property damage. After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage. After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property. NOTE: After this heading, read explanatory statements that require special emphasis. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: This symbol points out important safety information that, if not followed, could endanger personal! safety and/or property of others. This symbol points out potential explosion hazard. This symbol points out potential fire hazard. Generac Power Systems, Inc. This symbol points out potential electrical shock hazard. The operator is responsible for proper and safe use of the equipment. Generac strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. Generac also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency. OPERATION AND MAINTENANCE It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service. Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum. See the Generac Authorized Service Dealer for service aids and accessories. Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a do-it-yourself project. HOW TO OBTAIN SERVICE When the generator requires servicing or repairs, contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs. When contacting a Generac Authorized Service Dealer about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA CARD affixed to the unit. AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER, please call this number: OR Locate us on the web at:

3 Table of Contents Centurion kw Liquid-cooled Generators INTRODUCTION...IFC SAFETY RULES...2 Section 1 GENERAL INFORMATION Generator Transfer Switch Automatic System Operation Generator AC Connection Systems Main Circuit Breaker Generator Fuel System Engine Protective Devices Unpacking Lifting the Generator Specifications Fuel Consumption Reconfiguring the Fuel System Torque Specifications Engine Oil Recommendations Coolant Recommendations Before Installation...8 Section 2 INSTALLATION Standby Generator Installation Generator Location Generator Mounting and Support Basic Standby Electric System Emergency Circuit Isolation Method Total Circuit Isolation Method Grounding the Generator Generator AC Neutral Connections Transfer Switch Start Signal Connections Battery Installation Preparation Before Start-Up...12 Section 3 OPERATION Using an Engineered GTS Transfer Switch Control Console Components Manual Transfer and Startup Engine Governor Adjustments Retransfer and Shutdown Automatic Operation Weekly Exercise Cycle...15 Section MAINTENANCE Maintenance Performed by Authorized Service Dealers Cooling System Overload Protection for Engine DC Electrical System Checking Fluid Levels Maintenance Owner/Operator Can Perform Miscellaneous Maintenance Scheduled Maintenance...2 Section 5 TROUBLESHOOTING...23 Section 6 ELECTRICAL DATA...2 Section 7 EXPLODED VIEWS AND PARTS LISTS...28 Section 8 INTALLATION DIAGRAM...3 Section 9 NOTES... Section 1 WARRANTY...Back Cover Generac Power Systems, Inc. 1

4 IMPORTANT SAFETY INSTRUCTIONS Centurion kw Liquid-cooled Generators Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions. Generac cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the generator unsafe.!! SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.!! SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.!!! WARNING:! The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.! WARNING:! This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. DANGER Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment. Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator. Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.! GENERAL HAZARDS For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations. The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating. Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous. When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.! 2 Generac Power Systems, Inc.

5 IMPORTANT SAFETY INSTRUCTIONS Centurion kw Liquid-cooled Generators Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or ( ) first. Reconnect that cable last. Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. If people must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC), Article 25 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. Never disconnect the ground wire. Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected. Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock. Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy. Generators installed with an automatic transfer switch will crank and start automatically when NOR- MAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a Do Not Operate tag on the generator control panel and on the transfer switch. In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury. FIRE HAZARDS Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department. EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build-up of explosive gas. Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris. Generac generator sets may operate using one of several types of fuels. All fuel types are potentially FLAM- MABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service. Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly. Generac Power Systems, Inc. 3

6 Section 1 - General Information Centurion kw Liquid-cooled Generators 1.1 GENERATOR This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 12 and/or 2VAC, single-phase loads.! If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 71). Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy. 1.2 TRANSFER SWITCH This generator system includes a matched automatic transfer switch which is intended to be used in conjunction with the generator. It is supplied in a NEMA 3R enclosure. The NEMA 3R enclosure is weather resistant and can be used indoors or outdoors. Follow these rules: Install the transfer switch on a firm, sturdy supporting structure. To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and the mounting surface. Never install the switch where water or any corrosive substance might drip onto the enclosure. Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors. 1.3 AUTOMATIC SYSTEM OPERATION When this generator, along with a transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors UTILITY power source voltage. Should that voltage drop below a preset value, and remain at such a low state for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers load circuits so the generator can power them. When utility source voltage has been restored, the switch re-transfers back to the UTILITY source voltage and the generator then shuts down. Please reference the transfer switch manual for specific information. 1. GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single-phase, three-wire generator AC connection system (Figure 1.1). The stator assembly in this system consists of a pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 12VAC, 6 Hertz. When the two windings are connected in series, a 2VAC, 6 Hertz AC output results. Typically the two HOT leads in the circuit are wires 11 and. The NEUTRAL leads are the junction of Wires 22 and 33. The NEUTRAL is not grounded. Figure Generator AC Connection System Figure Main Circuit Breaker 1.5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory. The breaker for this unit is described in Figure 1.2. Model Rating Phase Actual Current C/B Rating* Circuit Breaker , NG A QN2, LP A QN2 * Amp Rating of C/B structured under model. Generac Power Systems, Inc.

7 Section 1 - General Information Centurion kw Liquid-cooled Generators 1.6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is necessary, refer to Section Fuel pressure for a natural gas set up should be five inches to 1 inches of water column (.18 to.5 psi) at all load ranges. Fuel pressure for an LP vapor set up should be 11 inches to 1 inches of water column (. to.5 psi) at all load ranges. NOTE: A seperate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability. NOTE: The Low Oil Pressure, High Coolant Temperature and Low Coolant Level are not monitored for the first 1 seconds of engine run time. Figure 1. - Low Oil Pressure Switch! Gaseous fuels such as natural and LP (propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas. 1.7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions: low oil pressure, high coolant temperature, engine overspeed, low coolant level or overcrank (Figure 1.3) HIGH COOLANT TEMPERATURE SWITCH This normally open (N.O.) thermostatic switch has sensing tip which is immersed in captive coolant. Should coolant temperature exceed about 23 F (11 C), the switch contacts close. This causes the engine to shut down automatically and turns on the high coolant temperature/low coolant level LED (Figure 1.5). Figure 1.5- High Coolant Temperature Switch Figure Engine Protective Devices High Coolant Temperature Switch Low Oil Pressure Switch Low Coolant Level Sensor LOW OIL PRESSURE SWITCH This switch is normally-closed (N.C.) but is held open by engine oil pressure during engine running. Should operating oil pressure drop below about 8-1 psi (55-68 kpa), the switch contacts close, the engine shuts down automatically, and the low oil pressure LED is turned ON (Figure 1.) LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down, the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automatically shuts down and turns on the high coolant temperature/low coolant level LED (Figure 1.6 on page 6). Generac Power Systems, Inc. 5

8 2 Section 1 General Information Centurion kw Liquid-cooled Generators Figure Low Coolant Level Sensor 1.7. OVERSPEED SHUTDOWN The engine control board receives AC frequency signals from an engine run winding in the alternator. Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaniously, the engine shuts down and the overspeed LED turns on. Should AC frequency exceed about 72 Hertz, circuit board action will automatically shutdown the engine (Figure 1.7). Figure Printed Circuit Board Assembly C U7 LED1 C9 C27 Q2 R D1 C26 C21 J LOW BATTERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11. VDC for one minute. Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 11. VDC. The control system will not attempt to start the engine if there is a low battery condition, however, if the engine is already running when the low battery condition occurs, the engine will continue to run as long as possible. Battery voltage is NOT monitored during the crank cycle ALARM RESET If the engine control board shuts down the generator for any of the above reasons, the engine remains stopped until the alarm is cleared by placing the AUTO/OFF/MANUAL switch into the OFF position DC FUSE These fuses are located on the front panel of the control system. They protect the panel wiring and components from damaging overload. Always remove the 15 amp main fuse before working on the generator. The unit will not start or crank if this fuse is blown. Replace the fuse with one of the same size, type, and rating (main AGC-15, battery charger AG). C3 C2 R1 RL1 RL2 1.8 UNPACKING R25 R9 R8 D UNPACKING PRECAUTIONS U1 PCB# E96 REV. L3 D19 J1 Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc RPM SENSOR LOSS If the engine control board does not receive a proper rpm signal from the starter during cranking or running, it shuts down the engine on rpm sensor loss and flash the overspeed LED OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine. The first crank cycle is a 15-second crank followed by a sevensecond rest. This is followed by five more crank cycles each with a seven-second crank followed by a seven-second rest. If the engine fails to start after all six attempts, the start attempt is stopped and the overcrank LED turned on. 6 Generac Power Systems, Inc INSPECTION After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consignor s memo of loss or damage. 1.9 LIFTING THE GENERATOR! When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 1 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.

9 Section 1 General Information Centurion kw Liquid-cooled Generators 1.1 SPECIFICATIONS GENERATOR SPECIFICATIONS Single-phase Model 993- Rated Max. Cont. 37 (NG), (LP) AC Power Output (kw) Rated voltage (volts) 12/2 No. of Rotor Poles Driven Speed of Rotor 18 Rotor Excitation System Direct excited brush type Type of Stator Wire Rotor/Stator Insulation Class F/H ENGINE SPECIFICATIONS Make...Chrysler Displacement liters Cylinder Arrangement...V-6 Valve Arrangement...Overhead Valve Firing Order Number of Main Bearings... Compression Ratio to 1 No. of Teeth on Flywheel...16 Ignition Timing at 18 rpm...3 degrees BTDC Spark Plug Gap...1.1mm (. in.) Recommended Spark Plugs Champion...RC12LC Oil Pressure psi Crankcase Oil Capacity... U.S. quarts (3.8 liters) Recommended Engine Oil...SAE 15W- Type of Cooling System...Pressurized, closed recovery Cooling Fan...Pusher Type Cooling System Capacity...5. U.S. gallons (19.3 liters) Recommended Coolant...Use a 5-5 mixture of ethylene glycol base and de-ionized water FUEL CONSUMPTION Natural Gas: % of Load 25% 5% 75% 1% m 3 /hr ft 3 /hr LP Vapor: % of Load 25% 5% 75% 1% m 3 /hr ft 3 /hr Fuel pressure for a natural gas set up should be five inches to 1 inches of water column (.18 to.5 psi) at all load ranges. Fuel pressure for an LP vapor set up should be 11 inches to 1 inches of water column (. to.5 psi) at all load ranges. NOTE: Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1 Btu per cubic foot. LP gas is rated at 252 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine conditions and other environmental factors RECONFIGURING THE FUEL SYSTEM NOTE: A separate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and could affect engine durability. NOTE: All models are configured for natural gas from the factory. To reconfigure the fuel system from NG to LP vapor, follow these steps: 1. Turn the main gas supply off. 2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 1.8). 3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator.. Remove pipe plug from Port Install brass hose fitting into Port Install pipe plug into Port Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs. 9. Make sure fuel supply is of the proper pressure and type for configuration. 1. Reverse the procedure to convert back to natural gas. PLUG Figure 1.8 Reconfigure the Fuel System Port 1 Port 2 NG FUEL SYSTEM FUEL HOSE BRASS HOSE FITTING OUT PORT 1 HOUSING PORTS FUEL HOSE BRASS HOSE FITTING OUT PORT 2 HOUSING PORTS LP FUEL SYSTEM PLUG Generac Power Systems, Inc. 7

10 Section 2 Installation Centurion kw Liquid-cooled Generators NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made.! Serious injury or damage may occur if not configured properly. Please consult an authorized Generac Service Dealer with any questions TORQUE SPECIFICATIONS Tighten the bolts from the middle out, in a crisscross pattern. Cylinder Head...5 ft.lb./15 ft.lb./15 ft.lb. Intake Manifold...8 in.lb./8 in.lb./8 in.lb. Exhaust Manifold...25 ft.lb. 1.1 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W- engine oil at the factory. Use a high-quality detergent oil classified For Service CC, SD, SE, SF. Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change: NOTE: Synthetic oil is highly recommended in any element with temperatures above 9 F or below 3 F.! DANGER Temperature Oil Grade (Recommended) Above 8 F (27 C) SAE 15W- 32 to 8 F (-1 to 27 C) SAE 15W- Below 32 F ( C) SAE 15W- Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti-freeze and half de-ionized water. Cooling system capacity is about 2 U.S. quarts (19.3 liters). Use only de-ionized water and only low silicate antifreeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 5-5 mixture.! Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromiumhydroxide ( green slime ) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. It is also recommend that any soluble oil inhibitor is NOT USED for this equipment BEFORE INSTALLATION Before installing this equipment, check the ratings of both the generator and the transfer switch. Read Emergency Isolation Method and Total Circuit Isolation Method in Sections 2.5 and 2.6. The generator s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. The critical (essential) loads may need to be grouped together and wired into a separate emergency distribution panel. The standard transfer switch has no sensing or controlling circuit boards. Instead, the generator control console houses a Printed Circuit Board Assembly, which controls all phases of operation, including engine start up and load transfer. 2.1 STANDBY GENERATOR INSTALLATION DANGER Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy. If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set. Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation. 8 Generac Power Systems, Inc.

11 Section 2 Installation Centurion kw Liquid-cooled Generators! After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations NFPA STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 2269: NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS- TEMS FOR HEALTH CARE FACILITIES. NFPA No. 22, STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No. 68, GUIDE FOR EXPLOSION VENTING NFPA No. 7, NATIONAL ELECTRICAL CODE. NFPA No. 3, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE. NFPA No. 1, INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS OTHER PUBLISHED STANDARDS In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is available: Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 99 University Avenue, Columbia, MO, ASAE EP-36.2, INSTALLATION AND MAINTE- NANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 295 Niles Road, St. Joseph, MI 985. A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYS- TEMS, available from the American National Standard Institute, 13 Broadway, New York, N.Y GENERATOR LOCATION Install the generator set, in its protective enclosure outdoors, where adequate cooling and ventilating air always is available. Consider these factors: Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit. Install the generator on high ground where water levels will not rise and endanger it. This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around. Allow sufficient room on all sides of the generator for maintenance and servicing. A good rule is to allow five feet of space on all sides. Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds. Install the generator as close as possible to the transfer switch. This reduces the length of wiring and conduit. Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REG- ULATE THE DISTANCE. 2.3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1/-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides. See Section 6 for generator major dimensions. 2. BASIC STANDBY ELECTRIC SYSTEM Figure 2.1 (on page 1) shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (GENERATOR) output are connected to an approved transfer switch. The transfer switch is required by electrical code and serves the following functions: Allows the LOAD circuits to be connected to only one power supply at a time. Prevents electrical backfeed between the generator and the UTILITY power circuits. Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker. Generac Power Systems, Inc. 9

12 Section 2 Installation Centurion kw Liquid-cooled Generators Figure 2.1 Basic Standby Electric System 2.7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a GROUND LUG (Figure 2.2) is provided on the generator mounting base. Consult a qualified electrician for grounding requirements in the area. Grounding procedures must meet local regulations. DANGER 2.5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, during utility power outages, consider using the emergency circuit isolation method. Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel. Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. When this method is used, it is difficult to overload the generator. The transfer switch must meet the following requirements: It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit. Have it installed between the building s main distribution panel and the emergency distribution panel. 2.6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed, use the Total Circuit Isolation Method. It is possible for the generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system. Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service. The transfer switch is installed between the utility service entrance and the building distribution panel. In accordance wtih electrical code, an approved means of service disconnect must be installed between the normal incoming utiltiy service entrance and the transfer switch. 1 Generac Power Systems, Inc. Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result. Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices. Figure 2.2 Generator Grounding Lug (typical) GROUNDING LUG 2.8 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends on the electrical characteristics of the particular installed generator. 2.9 TRANSFER SWITCH SIGNAL CONNECTIONS PRE-PACKAGED ATS If the generator is to be installed with a pre-packaged transfer switch, it is necessary to connect the control wires to the generator and set position two of the four-position dip switch to OFF.

13 Section 2 Installation Centurion kw Liquid-cooled Generators Setting switch two to OFF allows the control PCB to perform the ATS control functions. Control system interconnections consist of N1 and N2, and leads 23 and 19. Control system interconnection leads must be run in a conduit that is separate from the AC power lead. Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended below: MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 6 feet (1m) No. 18 AWG. 61 to 73 feet (223m) No. 16 AWG. 731 to 1,16 feet (35m) No. 1 AWG. 1,161 to 1,85 feet (565m) No. 12 AWG.! charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water GTS-TYPE ATS If the generator is to be installed with an engineered automatic transfer switch, such as a Generac GTStype switch, it is necessary to connect the two-wire start control system. Connect the two-wire start signal from the automatic transfer switch to the automatic start connection, which is located in the middle, on the bottom, inside the control panel. Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel. The conductors for the two-wire start circuit must be in their own conduit. (See Section 3.1 for further explanation.) NOTE: It will be necessary to provide a UTILITY supply to the integral battery charger. This battery charger is located in the engine generator control panel. Locate the six position terminal strip in the control panel. Connect a 2 VAC UTILITY supplied source to terminals labeled N1 and N2. The 2 VAC circuit should be protected by a 15A maximum rated circuit breaker. 2.1 BATTERY INSTALLATION! DANGER Standby generators installed with automatic transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after! Do not dispose of the battery in a fire. The battery is capable of exploding. Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes. The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles VENTED BATTERIES The electrolyte is a dilute sulfuric acid that is! harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed: Wear full eye protection and protective clothing, Where electrolyte contacts the skin, wash it off immediately with water, Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (5 grams) bicarbonate of soda to one gallon ( liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried. Lead acid batteries present a risk of fire because they generate hydrogen gas. The following procedure are to be followed: DO NOT SMOKE when near batteries, DO NOT cause flame or spark in battery area, and Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Generac Power Systems, Inc. 11

14 Section 3 Operation Centurion kw Liquid-cooled Generators Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. The recommended battery is Group 27F, 7 CCA/9 AH minimum capacity at F (-17.8 C). All batteries must be at 1 percent state-of-charge before they are installed on the generator. When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section, Maintenance. A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set. NOTE: Damage will result if the battery connections are made in reverse PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the Safety Rules on pages 2 and 3, as well as all other safety information in this manual, before attempting to operate this (and related) equipment PRIOR TO INITIAL START-UP Prior to initially starting the generator, it must! be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure. Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section, Maintenance TRANSFER SWITCH If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems (for additional information, see the applicable transfer switch manual for this unit). The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations FUEL SYSTEM Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See Specifications (Section 1.1) for more information GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark. Never operate the engine with the oil level below the dipstick ADD mark. See Specifications (Section 1.1) and Engine Oil Recommendations (Section 1.1). NOTE: This engine is shipped from the manufacturer with 15W- oil. This oil should be changed after 3 hours of operation ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See Specifications (Section 1.1) and Coolant (Section 1.15) BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (1 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8 of an inch (1 to 16 mm) ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and/or ground rod. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components. 12 Generac Power Systems, Inc.

15 FLASHING GREEN LED = NO UTILITY SENSE 5 FLASHING RED LED'S = EXERCISER NOT SET (IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON RED LED'S = INDIVIDUAL FAULT (SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS) 1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION. Section 3 - Operation Centurion kw Liquid-cooled Generators 3.1 USING AN ENGINEERED GTS TRANSFER SWITCH When required, the pre-packaged standby generator can be installed with an engineered Generac GTS type automatic transfer switch. In this application, the GTS is responsible for utility sensing, weekly exercising, and load transferring. Position two of the four-position dip switch is used to turn over this control to the GTS. Pos2 ON GTS Application The control board will NOT monitor utility. The control board will NOT perform a weekly exercise. (The five red LEDs will not flash in this mode.) The control board will NOT activate the transfer output. The control board WILL monitor all engine conditions and shut down on all the faults listed in this document. Pos2 OFF ATS Application (Included switch) The control board will perform all of the automatic features listed in this document. The two-wire start connections should NOT be used. GTS Mode Operation When in GTS mode, the control board will respond as follows based on the AUTO/OFF/MANUAL switch position. OFF The generator will not start and run in this position. MANUAL The control board will start and run the generator whenever the switch is in the manual position. AUTO The control board will monitor the two-wire start circuit. When a two-wire start is sent, the control board will immediately start and run the generator. When the two-wire start is removed, the control board will immediately stop the generator. NOTE: If the generator is installed in conjunction with an engineered GTS type transfer switch, refer to the applicable transfer switch manual for exact operating parameters and timing sequences. 3.2 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console (Figure 3.1) are as follows: Figure Home Standby Generator Panel AUTO/OFF/MANUAL SWITCH Use this three-position switch as follows: Set the switch to AUTO for fully automatic operation. See Automatic Operation (Section 3.5). Set switch to MANUAL position to crank and start the generator engine. Set switch to OFF position to shut down an operating engine. With OFF selected, operation will not be possible.! SET EXECISER TIME SWITCH A FUSE BATTERY CHARGER LED INDICATORS: A OFF ON SET EXERCISE TIME TO SET EXERCISER TIME OVER CRANK LOW BATTERY SYSTEM READY DANGER With switch set to AUTO, engine can crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/ MANUAL switch to OFF before working on or around the unit. Then, place a DO NOT OPERATE tag on control console FAULT INDICATOR LEDS These LEDs turn ON when one or more of the following engine faults occurs and the engine shuts down. Low Oil Pressure Overcrank Low Battery Overspeed/RPM Sensor Loss High Coolant Temperature/Low Coolant Level See Section 1.7 for further explanation of engine protection functions. Generac Power Systems, Inc. 13 AUTO OFF MANUAL E719 15A FUSE MAIN POWER RED LEDs GREEN LED AUTO/OFF/MANUAL SWITCH

16 2 Section 3 Operation Centurion kw Liquid-cooled Generators AMP FUSE This fuse protects the control console s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse. (Type AGC) AMP INLINE FUSE This fuse protects the battery charger against electrical overload. If the fuse needs to be replaced, use only an identical -amp replacement fuse (type AG). NOTE: This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically. See Weekly Exercise Cycle SYSTEM READY LED The System Ready LED (green) has two main proposes. First, the LED will be ON when the AUTO/OFF/MANUAL switch is in the AUTO position, utility is present, and there are no system alarms. This ON state indicates the system is fully ready for automatic operation. The system ready LED will be OFF when the switch is in the manual or OFF positions. The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes. The LED will flash at the rate of 1/2 second on, 1/2 second off if the utility sensing level is below the transfer back threshold. This secondary function is only available with dip switch two in the OFF position (engineered transfer switch application). 3. ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board. Connector J2 on the engine control board interfaces with a governor driver module and the Bosch throttle body. The engine governor has been set by the factory during final testing of the generator and, in most cases, should not be adjusted. If, however, adjustments are necessary, or a new engine control board is installed in the generator, the following procedure should be followed (Figure 3.2): 1. Set all three potentiometers (pots) fully counterclockwise. 2. Under no load condition, increase the GAIN pot as much as possible without causing instability. 3. Apply 1/, 1/2, 3/ and full load to the unit. Decrease the GAIN pot if there is instability at any load point.. Under full load condition, increase the stability pot until the unit returns to 6 Hertz (or 5 Hertz in 5 Hertz applications). 5. Reduce load to 3/, 1/2, 1/ and no load. Decrease the stability pot if there is instability at any load point. 6. Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot. If it is set too high, it may introduce oscillations at some load. It can be set to zero (full CCW) if a small amount causes oscillations at some load. Figure 3.2 Engine Governor Adjustment C3 C U7 LED1 C9 C27 Q2 R D1 C26 C21 J2 3.3 MANUAL TRANSFER AND START-UP To transfer electrical loads to the Standby (EMER- GENCY) power source side and start the engine manually, refer to the Owner s Manual of the particular transfer switch. R25 R9 U1 DIFFERENTIAL STABILITY E96 REV. PCB# C2 L3 R1 R8 D17 RL1 DIP SWITCH UNUSED GTS/ATS 5/6 HZ POSITION 1 5/6 HZ ON = 5 HZ OFF = 6 HZ D19 RL2 J1 POSITION 2 GTS/ATS Select ON = GTS OFF = ATS (standard mode) 1 Generac Power Systems, Inc.

17 Section 3 - Operation Centurion kw Liquid-cooled Generators 3.5 RETRANSFER AND SHUTDOWN When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as follows: Verify that utility power supply voltage to the transfer switch has been positively turned Off, using whatever means provided (such as utility main line circuit breaker). Set the generator s main circuit breaker to its Off or Open position. Let the generator engine run at no-load for a few minutes, to stabilize internal unit temperatures. On the generator console, set the Auto/Off/ Manual switch to Off. Wait for engine to come to a complete stop. For transfer to utility position, refer to the Owner s Manual of the particular transfer switch. Turn on the utility power supply to the transfer switch, using whatever means provided (such as a utility main line circuit breaker). The utility power source now powers the loads. 3.6 AUTOMATIC OPERATION To set the system for fully automatic operation, proceed as follows: Check that load circuits are connected to the utility power supply. Set the AUTO/OFF/MANUAL switch to its AUTO position. Set the generator main circuit breaker to its ON or CLOSED position. 3.7 WEEKLY EXERCISE CYCLE The engine control board will start and run the generator once every seven days for approximately 12 minutes. If utility should fail during this exercise period, the engine control board will transfer the load to the generator output and continue to run until utility returns. On the day, and at the time of day chosen for the generator to exercise, set the weekly exercise cycle as follows: 1. Place the AUTO/OFF/MANUAL switch in the auto position. 2. Press and hold the Set Exercise switch for three seconds, then release. At this time all five red LEDs will flash for approximately 1 seconds, then the engine will start and run for it s 12 minute exercise period, then shut down. The generator will now start and run each week at the same time. If DC power to the control board is lost, the weekly exercise setting will be lost. This is indicated by all five red LEDs continually flashing. In this state the generator will still start and run in manual mode, or automatically start and run if utility is lost while in Auto mode, but it will not perform a weekly exercise cycle. If a failure occurs while running in this mode, the five red LEDs will stop flashing, the individual fault LED will turn on and the engine will shut down. Once the AUTO/OFF/MANUAL switch has been switch to OFF, the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set. Figure Set Exercise Time Switch FUSE A BAT. CHARGER OFF ON E US FUS F S E SET EXERCISE TIME FUSE 15A MAIN E FUS FUS FUS E AUTO OFF MANUAL Generac Power Systems, Inc. 15

18 Section Maintenance Centurion kw Liquid-cooled Generators.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE DEALERS A. EVERY THREE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch.. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B. ONCE EVERY SIX MONTHS 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). C. ONCE ANNUALLY 1. Test engine governor. Adjust or repair, if needed. 2. Clean, inspect generator. 3. Flush cooling system. D. FIRST 1 OPERATING HOURS 1. Change engine oil and oil filter. (After initial change, service engine oil and filter at 15 operating hours or 6 months, whichever comes first.) 2. Retorque cylinder head. (See Torque Specs, Section 1.13.) 3. Retorque intake and exhaust manifold. (See Torque Specs, Section 1.13.) E. EVERY 5 OPERATING HOURS 1. Service air cleaner. 2. Check starter. 3. Check engine DC alternator..2 COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See Section 6 for installation drawings and vent locations.) The exhaust system parts from this product get extremely hot and remain hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system..3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15-amp fuse. These overcurrent protection devices will open if the circuit is overloaded.! If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.. CHECKING FLUID LEVELS..1 CHECK ENGINE OIL Check engine crankcase oil level (Figure.1) monthly, or prior to use. Remove oil dipstick and wipe dry with a clean, lint-free cloth. Install oil dipstick, then remove again. Oil should be between FULL and ADD marks. If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE FULL MARK. See Section 1.1 for recommended oils. Oil Filter Figure.1 - Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fill..2 BATTERY FLUID Check battery electrolyte fluid at least once weekly. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY. 16 Generac Power Systems, Inc.

19 Section Maintenance Centurion kw Liquid-cooled Generators..3 ENGINE COOLANT Check coolant level in coolant recovery bottle. See Specifications, Section 1.1. Add recommended coolant mixture as necessary. Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an authorized Generac Service Dealer. Inspect cooling system and coolant recovery system for leaks..5 MAINTENANCE OWNER/ OPERATOR CAN PERFORM.5.1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels. Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary..5.3 EXERCISE SYSTEM If the unit is not set up for automatic operation, start the generator engine at least once every seven days and let it run at least 12 minutes. See Section 3.6, Weekly Exercise Cycle..5. INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month. Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. Check hose clamps for tightness..5.5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels in Section PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks..5.8 CHECK FAN BELT Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt. Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required..5.9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor.! DANGER Do not attempt to adjust the governor. Only qualified service dealers should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed..5.1 CHANGING ENGINE OIL Refer to Maintenance Performed by authorized service dealers for engine oil and filter change frequencies. Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container. 3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP, and re-install into its retaining clip.. Turn OIL FILTER (Figure.2) counterclockwise and remove. Dispose of old filter. 5. Apply light coating of new engine oil to seal of new oil filter. Install FILTER and tighten by hand only. DO NOT OVERTIGHTEN. 6. Remove OIL FILL CAP. Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK FULL MARK. Crankcase oil capacity is. U.S. quarts (3.8 liters)..5.7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.! After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK. Generac Power Systems, Inc. 17

20 Section Maintenance Centurion kw Liquid-cooled Generators 7. Start engine and check for oil leaks. Oil Filter Figure.2 - Oil Filter.5.11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number A637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover. See the Service Schedule, Section 6, for air cleaner maintenance SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary. See Section Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the Service Schedule, Section 6, for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.1 mm (. inch) by carefully bending the ground electrode (Figure.3). Figure.3 Setting the Spark Plug Gap SET PLUG GAP AT 1.1 mm (. inch).5.13 COOLANT CHANGE Every year, have an authorized service dealer drain, flush and refill the cooling system. See SPECIFICA- TIONS (Section 1.1) for cooling system recommendations..6 MISCELLANEOUS MAINTENANCE.6.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water. Once each year, have the generator cleaned and inspected by an authorized service dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well. Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying..6.2 BATTERY All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: DO NOT use jumper cables and a booster battery to crank or start the generator engine. DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames. Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately. Always wear safety glasses, rubber apron and gloves when handling a battery. Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury. 18 Generac Power Systems, Inc.

21 Section Maintenance Centurion kw Liquid-cooled Generators.6.3 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule, Section 6. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. 3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer.!! DANGER Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If the fluid is spilled, flush the affected area immediately with clear water. Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.! Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected. Be sure the UTILITY power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion..6. BATTERY REPLACEMENT When replacing batteries, use the same number and the type of battery that follows: BCI Group No. 27F CCA deg. F NOTE: The BCI number should be located directly on the battery. PERIODIC REPLACEMENT PARTS Part Name Generac s Part Number Oil Filter # E715 Radiator Cap # 6627 Air Cleaner # A637 Spark Plug Champion # RC12LC Generac Power Systems, Inc. 19

22 Section Maintenance Centurion kw Liquid-cooled Generators.7 SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the previous maintenance interval to determine the next required maintenance interval. Service Maintenance Interval Information: The various service maintenance intervals are designated by interval numbers as follows: 1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any potential problem areas. Performed monthly, this inspection requires approximately.5 man-hours per unit to complete. This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning: To prevent injury, perform the following steps in the order indicated before starting any maintenance: Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO-OFF-MANUAL switch to the OFF position. Remove the control panel fuse. Turn off the battery charger. Remove the negative battery cable. The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits. Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required. 2 A break-in service inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed ONLY ONCE following the first three months or the first 3 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer. 3 An operational inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed semi-annually or following each 5 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Generac Service Dealer. A mid-level inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or following each 1 hours of operation of the unit and requires approximately. man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Generac Service Dealer. 2 Generac Power Systems, Inc.

23 Section Maintenance Centurion kw Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Datemonthly Initials) Break-in Initials) annually Initials) Annually Initials) 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary.. Check the engine coolant thermal protection level. Correct as necessary. 5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary. 6. Check the air inlets and outlets for debris. Clean as necessary. 7. Check the battery electrolyte level if accessible. Adjust as necessary. 8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary. 9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary. 1. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary. 11. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary. 12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. Generac Power Systems, Inc. 21

24 Section Maintenance Centurion kw Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Datemonthly Initials) Break-in Initials) annually Initials) Annually Initials) 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 1. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 15. Change the engine oil. 16. Replace the engine oil filter(s). 17. Replace the engine air filter(s). 18. Replace the engine fuel filter(s) on diesel engine driven units and re-prime the fuel system. 19. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessary. 2. Perform a 5 minute no-load operational run of the unit looking for any post service problems. 21. Return the unit to standby setup for operation when required. 22 Generac Power Systems, Inc.

25 Section 5 Troubleshooting Centurion kw Liquid-cooled Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won t crank amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. Replace contactor.. Defective starter motor.. Replace starter motor. 5. Dead or Defective Battery. 5. Remove, change or replace battery. 6. -amp fuse blown. 6. Replace fuse. Engine cranks, but won't start 1. Out of fuel. 1. Replenish fuel. 2. Fuel solenoid (FS) is defective 2. Replace solenoid. 3. Open Wire #1 from Engine Control 3. Reconnect wire. circuit board.. Spark plugs defective.. Clean, regap or replace plugs. Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed. damaged. 2. Plugged fuel line. 2. Unclog fuel line. 3. Defective spark plugs. 3. Clean, regap or replace plugs. Engine starts, then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed. 2. Engine is overheated. 2. Check cooling system for leaks. 3. Defective Low Oil Pressure Switch 3. Replace switch.. Defective Coolant Temperature Switch. Replace switch. 5. Defective Control Module circuit board. 5. Replace board. 6. Coolant Level is Low. 6. Repair leak - Add coolant. 7. Defective Low Coolant Level Switch 7. Replace Switch. AUTO/OFF/MANUAL Switch at, 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch. OFF engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire. AUTO/OFF/MANUAL switch and Control Module circuit board. 3. Defective Control Module circuit board 3. Replace board. No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED. 2. Check circuit breaker & fuses. 2. Reset and replace, if necessary. 3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.. Generator internal failure.. Contact an Authorized Generac Dealer. 5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and attempt restart. NOTE: Under normal operating conditions, if repair of generator set or replacement of any parts is necessary during the warranty period, you must contact an authorized service dealer. Failure to have the repair or replacement performed by the authorized service dealer will result in non-coverage of warranty repair cost. Generac Power Systems, Inc. 23

26 Section 6 - Electrical Data Centurion kw Liquid-cooled Generators Wiring Diagram Engine Drawing No. E TB CB AVR A RL1 N1 N2 UTILITY FROM T/SW UTILITY FROM T/SW A TRANSFER RELAY COIL TRANSFER RELAY COIL A 15E F2 C - REMOTE START NO - REMOTE START IC 1b 1 1a OA 13A A 15 SW2 2b 2a TRANSFER SWITCH CUSTOMER CONNECTION 1 F1 15 LEGEND: AVR - BA - B/C - BC1 - CB1 - CB2 - D1 - F1-2 Generac Power Systems, Inc. 1 2 B/C 2 SW1 11 NB CB NEUTRAL A 22A TR N1 AUTOMATIC VOLTAGE REGULATOR BRUSH ASSEMLY (GENERATOR) BATTERY CHARGER BULKHEAD CONNECTOR 1 (ENGINE) CIRCUIT BREAKER (OUTPUT) CIRCUIT BREAKER (EXCITATION) DIODE [FIELD BOOST] FUSE, BAT. POWER (15A AGC TYPE) TR1 N2 BA STATOR N2 N D1 55 LEGEND {CONT.]: F2 - FUSE, B/C (A AGC TYPE) ICT - INTERCONNECT. TERMINAL BLOCK NB - NEUTRAL BLOCK RL1 - RELAY 1 SW1 - AUTO/OFF/MANUAL SWITCH SW2 - SET EXERCISER SWITCH TB1 - TERMINAL BLOCK 1 TR1 - TRANSFORMER 1 (56 VA 2/16 VAC) TR2 - TRANSFORMER 2 (6 VA 2/16 VAC) 6 BC1 A 13 1A 15A 15E

27 1 1 Section 6 - Electrical Data Centurion kw Liquid-cooled Generators Wiring Diagram Engine Drawing No. E8115 PCB J N/C 8 1 PCB J A E A C1 A 13 1A 15A 15E CC BAT 13 FS GND2 A 1 SM BLK RED GND1 LEGEND: ALT - D.C. CHARGE ALTERNATOR BAT - 12VDC BATTERY C1 - CONNECTOR 1 (ENGINE) CC - STARTER CONTACTOR DEG - DRIVER ELEC. GOVERNOR DIST- DISTRIBUTOR FS - FUEL SOLENOID GND1- GROUND (SENSING/LOW AMP) GND2- GROUND (POWER/HIGH AMP) GOV - ELEC. GOVERNOR ACTUATOR JB ALT HCT WLS MP1 DEG GOV N/C IM A 5 9A SLD R1 LEGEND [CONT.]: HCT - HIGH COOLANT TEMP SWITCH IC - IGNITION COIL IM - IGNITION MODULE J-1 - JUNCTION 1 (ON PCB) J-2 - JUNCTION 2 (ON PCB) JB - JUNCTION BLOCK (RUN POWER) LOS - LOW OIL PRESSURE SWITCH MP1 - MAGNETIC PICK-UP R1-5 WATT RESISTOR SM - STARTER MOTOR WLS - COOLANT LEVEL SWITCH Generac Power Systems, Inc IC 9A FRONT A 9A DIST SHIELD 2

28 Section 6 - Electrical Data Centurion kw Liquid-cooled Generators Electrical Schematic Engine Drawing No. E8116 LEGEND: AR - AS - AVR - BA - B/C - BCW - CB1 - CB2 - D1 - DPE - ALTERNATOR ROTOR ALTERNATOR STATOR AUTOMATIC VOLTAGE REGULATOR BRUSH ASSEMLY (GENERATOR) BATTERY CHARGER BATTERY CAHRGE WINDING CIRCUIT BREAKER (OUTPUT) CIRCUIT BREAKER (EXCITATION) DIODE [FIELD BOOST] DISPLACED PHASE EXCITATION LEGEND {CONT.]: F1 - FUSE, BAT. POWER (15A AGC TYPE) F2 - FUSE, B/C (A AGC TYPE) ICT - TERMINAL BLOCK, INTERCONNECT. NB - NEUTRAL BLOCK RL1 - RELAY 1 SW1 - SWITCH, AUTO/OFF/MANUAL SW2 - SWITCH, SET EXERCISER TR1 - TRANSFORMER 1 (56 VA 2/16 VAC) TR2 - TRANSFORMER 2 (6 VA 2/16 VAC) 66 RL A 1 BA 6 DPE AR 5 22 AS 6 5 CB1 D1 E1 NB CUSTOMER CONNECTION 12/2V 1-PHASE CB2 E N1 N2 N1 N TRANSFER SWITCH CONNECTION AVR A N ICT TR A N A A 15 N TR2 1 2 F2 5 F N E 15A SW SW2 3 6 SHOWN IN OFF POSITION 1 2a 2 A 13 1A 15A 15E BULKHEAD CONNECTOR (BC1) 26 Generac Power Systems, Inc.

29 Section 6 - Electrical Data Centurion kw Liquid-cooled Generators Electrical Schematic Engine Drawing No. E8116 PCB J N/C 8 1 PCB J A E A CC CC RED 13 JB 12V BATTERY SC (+) (-) SM SC BLACK ALT DEG IM A A SLD GOV N/C R A A A 79 SHIELD LOS C1 A 13 1A 15A 15E GND2 FS A WLS GND1 LEGEND: ALT - D.C. CHARGE ALTERNATOR BAT - 12VDC BATTERY C1 - CONNECTOR 1 (ENGINE) CC - STARTER CONTACTOR DEG - DRIVER ELEC. GOVERNOR DIST- DISTRIBUTOR FS - FUEL SOLENOID GND1- GROUND (SENSING/LOW AMP) GND2- GROUND (POWER/HIGH AMP) GOV - ELEC. GOVERNOR ACTUATOR HCT LEGEND [CONT.]: HCT - HIGH COOLANT TEMP SWITCH IC - IGNITION COIL IM - IGNITION MODULE J-1 - JUNCTION 1 (ON PCB) J-2 - JUNCTION 2 (ON PCB) JB - JUNCTION BLOCK (RUN POWER) LOS - LOW OIL PRESSURE SWITCH MP1 - MAGNETIC PICK-UP R1-5 WATT RESISTOR SM - STARTER MOTOR WLS - COOLANT LEVEL SWITCH FRONT DIST Generac Power Systems, Inc. 27

30 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Mounting Base Drawing No. E88-A TO ENGINE MOUNT TO ENGINE BLOCK TO STARTER BOLT TO 31 STARTER CONTACTOR HARNESS WIRE REAR BEARING CARRIER Generac Power Systems, Inc.

31 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Mounting Base Drawing No. E88-A ITEM PART NO. QTY. DESCRIPTION 1 E WELDMENT MTG BASE 3.9L CRYSLR NUT FLANGED HEX M DAMPENER VIBRATION BLUE SPACER.9 X.62 X 1.87 PWDR/ZNC DAMPENER VIBRATION WASHER FLAT M SCREW HHC M X 8 G ASSY WIRE 15." SCREW HHTT M6-1. X 2 BP SCREW HHC M6-1. X 16 BP LUG SLDLSS #2-#8 X 17/6 CU WASHER SHAKEPROOF EXT 1/ STL WASHER LOCK M6-1/ WASHER FLAT M6-1/ ZINC NUT HEX M6-1. G8 YEL CHR 16 A /2" BUTTON PLUG WASHER SHAKEPROOF EXT 7/16 STL 19 E ENGINE MOUNT (3.9L CHRYSLER) WASHER SHAKEPROOF EXT 5/16 STL WASHER LOCK M8-5/ NUT HEX M G8 YEL CHR 23* SCREW HHC M1-1.5 X 2 G8.8 2* WASHER LOCK M1 25* WASHER FLAT 3/8-M1 ZINC 26* 5593M 1 CLAMP VINYL.75 X.33 Z NUT HEX LOCK M NY INS HOLD DOWN BATTERY HOLD DOWN BATTERY REF. BATT 12VDC 9-AH 27F D 1 CABLE BATT RED # X J 1 CABLE BATT BLK #1 X EARTH STRAP SCREW HHC 3/8-16 X 1 G WASHER LOCK 3/ WASHER FLAT 3/8 ZINC BOOT BATTERY CABLE BATTERY POST COVWER (BLACK) A 1 BATTERY POST COVWER (RED) A1 2 SCREW HHC M X 6 G8.8 FT NUT TOP LOCK FL M SPRING CLIP HOLDER SCREW HHTT M-.7 X 8 BP *NOT SHOWN-USED TO HOLD DOWN I/N 32. Generac Power Systems, Inc. 29

32 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Enclosure Drawing No. E839-E 38 3 LATCH DETAIL STATES FOAM IS ON NEAR SIDE STATES FOAM IS ON FAR SIDE 33 RADIATOR TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION. SECURE AS SHOWN. 36 TO "A" "B" 52 SEE LATCH DETAIL "A" "B" TO "B" (2-PLCS) Generac Power Systems, Inc.

33 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Enclosure Drawing No. E839-E ITEM PART NO. QTY. DESCRIPTION 1 E811 1 INTAKE DUCT HSB 2 E82 1 DUCT DISCHARGE RH FRONT 3 E81 1 DUCT DISCHARGE LH FRONT C25 62 SCREW TH-FRM M6-1 X 16 N WA Z/JS 5 E787 1 BAFFLE REAR BOTTOM 6 E788 1 POST CORNER LH REAR 7 E789 1 POST CORNER RH REAR 8 E BAFFLE REAR TOP 9 E DOOR COMPARTMENT SIDE 1 E SUPPORT, R/H SIDE FOAM STRIP 3/" WIDE X 3/16" THK (" LG) 12 A2115 WASHER NYLON E8 1 BRACKET STIFFENER LH FRONT 1 D2538A 1 HINGE LIFT OFF TYPE B KNUCKLE 15 D HINGE LIFT OFF TYPE B PIN SCREW HHC M6-1. X 12 G WASHER LOCK M6-1/ WASHER FLAT 1/-M6 ZINC 19 E757 2 GAS SPRING 2 E7571 BALL STUD GAS SPRING MOUNT NUT HEX 5/16-18 LOCK 22 E7662 SCREW WING M6-1. X D2537A 1 HINGE LIFT OFF TYPE A KNUCKLE 2 D HINGE LIFT OFF TYPE A PIN 25 D223 2 TRIM VINYL SELF GRIPPING (91" LG) 26 E BRACKET STIFFENING BACK 27 E81 1 MUFFLER BOX 28 E86 1 ROOF W/GAS SPRING MNT 3.L FRD 29 E BRACE FRONT TOP 3 D337A 1 LATCH 1/ TURN NONLOCKING 31 C PAWL DOOR HSB 32 E779 1 SUPPORT LH SIDE 33 E852 1 MUFFLER BOX TOP 3 D337 1 LATCH QUARTER TURN LOCKING 35 E87 1 POST CORNER LH FRONT 36 E88 1 POST CORNER RH FRONT 37 E BRACE FRONT BOTTOM 38 E855 1 DUCT DISCHARGE MID FRONT WASHER SHAKEPROOF EXT 1/ STL ASSY GRD WIRE 99HSB ASSEMBLY BASE-DOOR GROUND WIRE NUT HEX M6 X 1. G8 YEL CHR 3 E BRACKET STIFFENER LH FRONT D223 1 TRIM VINYL SELF GRIPPING (165.5"LG) 5 * E82 1 KIT INSULATION 3.9L HSB 51 E7829A 1 AI ROOF PANEL 1 52 E7829B 2 AI DOOR PANEL 53 E7829P AI CORNER POST PANEL 1 5 E7829R 2 AI CORNER POST PANEL 2 55 E7829S 1 AI SUPPORT LH PANEL 56 E7829T 1 AI SUPPORT RH PANEL 57 E7829N 2 AI ROOF PANEL WASHER SELF LOCKING DOME * ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF E82 Generac Power Systems, Inc. 31

34 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Control Panel Drawing No. E7118-G 32 Generac Power Systems, Inc.

35 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Control Panel Drawing No. E7118-G ITEM PART NO. QTY. DESCRIPTION 1 E CONTROL BOX HSB 2 E COVER FRONT PANEL HSB 3 E COVER TOP PANEL HSB E DECAL WARNINGS HSB 5 E719 1 DECAL CONTROLS HSB 6 E9 1 SWITCH ROC DPDT ON-OFF-ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15A X AGC B 1 FUSE A SLO BLO GLASS FITTING CONDUIT 9D 3/8" DECAL DANGER HIGH VOLTAGE 13 C TRANSFRMR 16V 6VA TRANSFORMER 16V 56VA PCB SUPPORT SNAP-IN 1/" 16 E ASSY PCB HSB CONTROLLER 3.9L E95 1 ASSY PCB HSB CONTRLR 3.L FORD ASSY VOLTAGE REGULATOR 6HZ 18 E6875A 1 RELAY 12VDC C FORM W/DIODE 19 E6881 * REF. SOCKET RELAY 2 C5139 * REF. CONN DEUTSCH RECEPT GY/FLN 21 E512 * REF. CONN DEUTSCH RECEPT WDGE BLKHD 22 E ASSY BOSCH GOV DRIVER CIRCT BRK 5.5 X 1 ETA 6-5-P 2 D57A 1 ASSY 2A 12V UL BATTERY CHARGER 25 E251 1 FITTING CONDUIT STR 1-1/2" 26 A957 1 DECAL NEUTRAL 27 E DECALCUSTOMER CNNCTN XFER SW * REF. BLOCK TERM 2A 6 X 6 X 11V 29 D3719B 1 DECAL CUSTOMER CNNCTN E1 E3 N JUNCTION BLOCK 3/ E CB 15A2P2V S QN2 LL E CB 2A2P2V S QN2 LL 32 E366 1 BASE QN CIRCUIT BREAKER 33 E7539A 1 DECAL TB1 HSB CONTROL PANEL ITEM PART NO. QTY. DESCRIPTION 3 D698 * REF. BLOCK TERM 2A 6 X 3 X 11V 35 E BRACKET CB X C DECAL WARNING ELECTRICAL SHOCK 37 C DECAL AVR COVER 38 A11B 1 COVER PLATE, AVR 39 E HARNESS CNTRL PNL 3.L FORD (NOT SHOWN) E SCREW PPPH HI-LO #-2 X 3/ SCREW HHTT M5-.8 X 1 BP 2 C511 1 CONN DEUTSCH GASKET 8/12 POS DT 3 C SCREW PHTT #6-32 X 3/8 ZYC C2323 SCREW PHTT #6-32 X 5/8 ZYC WASHER LOCK #6 6 C2265 SCREW PHTT M-.7 X 12 ZYC WASHER LOCK #8-M SCREW PPHM M5-.8 X 3 ZINC SCREW HHTT M5-.8 X WASHER LOCK # WASHER FLAT #1 ZINC NUT HEX M5-.8 G8 YEL CHR SCREW HHTT M6-1. X 12 ZINC SCREW HHC M6-1. X 2 G WASHER LOCK M6-1/ WASHER FLAT 1/-M6 ZINC WIRE ASSY 3" X (2) 3/16" TABS WASHER MICA WASHER SHAKEPROOF EXT #1 STL HEATSINK WASHER STEP NYLON RECTIFIER MSC 12A 6V 1N126R NUT HEX #1-32 STEEL WASHER FLAT #6 ZINC SCREW HHC M6-1. X 3 G A2115 WASHER NYLON C25 SCREW THF M6-1 X 16 N WA Z/JS * ITEMS INCLUDED AS PART OF I/N 39 Generac Power Systems, Inc. 33

36 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Engine Drawing No. E8121-C 3 Generac Power Systems, Inc.

37 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Engine Drawing No. E8121-C ITEM PART NO. QTY. DESCRIPTION 1 E58A 1 FLEXPLATE 3.9L HSB 2 E777 1 MACHINING, 3.9L ENGINE ADAPTOR 3 E673 1 COVER, FLYWHEEL ACCESS E8336 REF REWORK, 3.9L CHRYSLER ENGINE 5 E781 2 GASKET, THERMOSTAT ADAPTOR 6 E725 1 MACH, THERM ADAPTOR 3.9L CHRY 7 E BRACKET, IGNITION COIL 8 E COIL IGNITION 3.9L CHRYSLER SCREW HHC M6-1. X 16 G8.8 1 E BOLT, AUTO TRANS CRANKSHAFT 11 E BRACKET, ALTERNATOR 12 E779 1 FAN SPACER, ENGINE COOLING WASHER LOCK M6-1/ WASHER FLAT 1/-M6 ZINC SCREW HHC M6-1. X 35 G8.8 BLK NUT HEX M6 X 1. G8 YEL CHR SCREW HHC 3/8-16 X 1 G WASHER FLAT 3/8-M1 ZINC WASHER LOCK 3/8 2 E977 1 STARTER, 12 VOLT WASHER LOCK M8-5/ SCREW SHC M X 3 G JUNCTION BLOCK 3/ WASHER NYLON.5 X.87 X SCREW HHTT M5-.8 X RELAY SOLENOID 12VDC PNL MNT 27 D22M 1 ASSY MAGPICKUP(3/8-2 MALE) PLUG PLASTIC 3/8 NPT 29 E992B REF PLUG EXPANSION 21/32" O.D. (WATER PUMP) (QTY 1) 3 E992A REF PLUG EXPANSION 1.1 O.D. (INJCTOR HOLE) (QTY 6) 31 E775 1 COOLING FAN 1-BLADE (KYSAIR) 32 E785 1 CLUTCH, COOLING FAN 33 E TENSIONER W/BRACKET 3 E PULLEY CRANKSHAFT 3.9L CRYSLR 35 E561 1 ASSY,WATER LEVEL SENSOR C/E PL SENSOR HI COOLANT SHUTDOWN PLUG STD PIPE 1/8 SOCKET HEAD 38 A858 1 SWITCH,OIL PRESSURE, 1PSI, 2POL ITEM PART NO. QTY. DESCRIPTION A 1 PLUG PIPE 1/ CSK W/ VIBRA SL PLUG STD PIPE 3/8 COUNTER- SUNK WASHER FLAT 5/16-M8 ZINC SCREW HHC 5/16-18 X 1 G SCREW HHC M1-1.5 X 2 G WASHER LOCK M1 5 A1232A 1 ASSEMBLY, D.C. ALTERNATOR 6 A781B 1 PULLEY POLY-V 82 OD NUT HEX M1-1.5 G8 YEL CHR SCREW HHC 5/16-18 X 2 G5 9 E795 1 TUBE, DIPSTICK 3.9L CHRYSLER 5 E DIPSTICK OIL LEVEL 3.9L CRYSLR 51 E85 1 BRACKET, DIPSTICK TUBE 52 E715 1 OIL FILTER, 3.9L CHRYSLER SCREW HHC M6-1. X 2 G SCREW HHC M1-1.5 X 85 G SCREW HHC 3/8-16 X 1-1/2 G SPACER.1 X.75 X.39 ST/ZNC SCREW SHC 3/8-16 X 1.25 G8.8 Z 58 E997 2 CAP VINYL 3/8"ID X 1"DP BLK 59 D388A 1 BELT SERPENTINE 7" 6 E795 1 CABLE IGN COIL 3.9L CHRYSLER 61 E839 1 ASSY, IGNITION MODULE 3.9L SPACER.19 X.31 X.5 PL SCREW HHTT #1-32 X 1.75 CZ ADP OIL DRN 1/ E866 2 SCREW PPH TAPPING # X 3/8"LG 66 E862 REF ASSEMBLY, RESISTOR 67 E HARNESS, 3.9L CHRYSLER ENGINE (NOT SHOWN) 68 E HARNESS, IGNITION 3.9L CHRY (NOT SHOWN) 69 E PLATE, FLEX DISK SPACER SCREW SHC M1-1.5 X 25 G E CAP VINYL 1/"ID X 1"DP BLK 72 F1A 2 HEAT SHEILD, L/H SIDE 73 C25 2 SCREW THF M6-1X16 N WA Z/JS BARBED EL 9 3/8 NPT X 3/ C 1 HOSE OIL DRAIN ASSY 21" J REF HOSE CLAMP BAND 5/8" 77 F1 1 HEAT SHIELD, R/H SIDE Generac Power Systems, Inc. 35

38 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Radiator Drawing No. E812-D "A" TO ENGIN WATER PUMP TO THERMOSTAT HOUSING Generac Power Systems, Inc.

39 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Radiator Drawing No. E812-D ITEM PART NO. QTY. DESCRIPTION 1 D7825A 1 RADIATOR COPPER BRASS 2 D717C 1 VENTURI,3.9L CRYSLR HSB 22"FAN 3 E76 1 RADIATOR SUPPORT L/H SIDE E792 1 HOSE LOWER RADIATOR 5 D785 1 RADIATOR HOSE, UPPER 6 D FAN GUARD, TOP 7 D FAN GUARD, BOTTOM 8 E726 1 BRACKET, WATER BOTTLE 1.5L MIT TANK COOLANT RECOVERY CLAMP HOSE # C 1 HOSE OIL DRAIN ASSY 21" SCREW CRIMPTITE 1/-2 X 5/8 15 C25 5 SCREW TH-FRM M6-1X16 N WA Z/JS TAPE FOAM 1 X 1 (27"LG) C 1 CLAMP HOSE BAND 1/ HOSE 9/32 ID (3" LG) 19 A SCREW SWAGE 1-32 X 5/16 Z/YC 2 E76A 1 RADIATOR SUPPORT R/H SIDE BARBED STR 1/NPT X 3/ SPRING CLIP HOLDER SCREW HHC M1-1.5 X 2 G WASHER FLAT 3/8-M1 ZINC WASHER LOCK M NUT HEX M1-1.5 G8 YEL CHR Generac Power Systems, Inc. 37

40 Section 7 - Exploded Views and Parts Centurion kw Liquid-cooled Generators Fuel System Drawing No. E8122-F 5 TO ENGINE "B" TO "B" TO INTAKE MANIFOLD 38 Generac Power Systems, Inc.